Do you know the pelletized feed manufacturing process?
ICC Brazil Consulting shares solutions that are one step ahead of factories’ needs and the main mistakes that affect management productivity.
2020 has been an atypical year in every way. Due to the coronavirus pandemic, part of our team is working from home, and the other continues to work in the factories. Therefore, it was necessary to reformulate our way of working, especially concerning managing demands, so that errors would not harm business and growth opportunities in pelleted feed manufacturing.
ICC Brazil, a pioneer company in producing innovative solutions for animal nutrition based on yeast additives, has listed some trends so that companies are one step ahead of their needs and increase management productivity.
According to consultant Françuele Alexandre de Medeiros, one of the trends is the complete automation of the plant’s operation; the operator performs any machine and equipment adjustment via tablet or device with a wi-fi connection. Integrated automation promotes a standard through pre-defined specifications for process and product.
Françuele says that the systems for supplying process silos by pneumatic transport also help production to increase productivity. This is because the pre-mixer pneumatic transport eliminates the risk of cross-contamination and losses in raw materials. Post-mixer pneumatic transport avoids demixing, cross-contamination, and maintains the particles/pellets’ physical characteristics.
The consultant also points out that, with the use of an individual scale per dosing silo, it is possible to increase the number of batches per hour to obtain a higher degree of precision in weighing/dosing, less time for each batch cycle, and a higher line ton/h rate.
Regarding errors and challenges, Françuele points out flaws in the project’s elaboration. “Since it is a continuous flow process, sometimes poorly designed projects create bottlenecks in the flow (oscillations in the flow due to capacities smaller than the nominal project), thus reducing the tons/hour production capacity rate,” she says.
One of the great challenges for feed factories and, in general, is the effective implementation of quality assurance programs. “Actual implementation of quality programs from scratch on the industry floor has been a major challenge for feed factories. Whether mandatory by regulatory bodies such as GMP (Good Manufacturing Practices), regulated by MAPA (Ministry Agriculture, Livestock and Supply), cleaning and 5S organization (business quality management program developed in Japan that aims to improve aspects such as organization, cleaning, and standardization), or even food security HACCP (Hazard Analysis and Critical Control Points)”, he explains. He also emphasizes that a well-implemented quality program contributes both to the process and to the fulfillment of pre-established standards, making it possible to achieve the expected results for the product quality and the plant’s productive efficiency.
According to Françuele, there was a lack of knowledge about the process on the part of the staff, not only operational but also management-wise. “We have identified numerous opportunities for process improvements. Many plants have difficulty meeting product specifications, most of which have pelletizing processes, and it is common for deviations to occur, which significantly compromise the quality of the end product. Therefore, we have decided to develop a material to provide companies valuable content and help them reach the maximum potential in their productions. All the information is available on the website, and the webinar can be accessed on the ICC Brazil YouTube channel”.
About ICC Brazil
ICC Brazil is a company that creates solutions for animal health and nutrition. Recognized in Brazil and abroad for its innovative capacity, our company develops yeast-based products obtained through the sugar cane fermentation process. Since 1992, ICC has been working with Universities and national and international Research Centers, and over 200 in vivo and in vitro studies have been carried out in different areas of animal production, ensuring the quality and efficiency of our products. http://www.iccbrazil.com
Posted in 18 November of 2020